Size effect characteristics and influences on fatigue behavior of laser powder bed fusion of thin wall GRCop-42 copper alloy

Demeneghi, Gabriel; Gradl, Paul; Mayeur, Jason R.; Hazeli, Kavan

doi:10.1016/j.heliyon.2024.e28679

Title: Size effect characteristics and influences on fatigue behavior of laser powder bed fusion of thin wall GRCop-42 copper alloy

Journal Article · 26 March 2024 · Heliyon

DOI: https://doi.org/10.1016/j.heliyon.2024.e28679 · OSTI ID:2333845

^[1]; Gradl, Paul ^[2];

^[3]; Hazeli, Kavan ^[4]

NASA Marshall Space Flight Center (MSFC), Huntsville, AL (United States); Univ. of Alabama, Huntsville, AL (United States)
Univ. of Alabama, Huntsville, AL (United States)
Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)
Univ. of Arizona, Tucson, AZ (United States)

Size effects, influencing a material's strength, elongation, fatigue limit, and longevity, depend on the operative and dominant deformation and failure mechanisms. This study explores the size effects in additive manufactured (AM) GRCop-42 (Cu-4at%Cr-2at%Nb) thin wall structures fabricated via laser-powder bed fusion (L-PBF) and their impact on fatigue life. The influence of internal defects and surface topography on the fatigue life of specimens in both as-built and hot isostatic pressed (HIP) conditions across different thicknesses is investigated. Where micro-computed tomography (μCT) was used to quantify the internal porosity of as-built, pristine HIP'd, and fatigued HIP'd specimens, and laser microscopy was employed to quantify the surface topography of specimens prior to fatigue. Additionally, quasi-static tests were used to establish baseline mechanical properties (i.e. yield strength (YS), ultimate tensile strength (UTS), and elongation) to frame fatigue testing conditions. Results indicate a significant enhancement in fatigue life for HIP'd specimens for both thicknesses, with internal defects depicting a greater impact than surface topography. Furthermore, fractographic analysis suggests that thicker specimens exhibit higher resistance to crack propagation during fatigue testing in the absence of substantial porosity. Thus, the size effects observed on the fatigue life of L-PBF GRCop-42 appears to be dominated by internal defects.

View Accepted Manuscript (DOE)

Cite

Export

Save

Research Organization:: Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)

Sponsoring Organization:: USDOE

Grant/Contract Number:: AC05-00OR22725

OSTI ID:: 2333845

Journal Information:: Heliyon, Journal Name: Heliyon Journal Issue: 7 Vol. 10; ISSN 2405-8440

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

References (38)

Understanding slip activity and void initiation in metals using machine learning-based microscopy analysis Indeck, Joseph; Cereceda, David; Mayeur, Jason R. Materials Science and Engineering: A, Vol. 838 https://doi.org/10.1016/j.msea.2022.142738	journal	March 2022
Size effect due to contour laser scanning in 316L stainless steel produced by laser powder bed fusion Yu, Jaehyun; Kim, Dohyung; Ha, Kyeongsik Journal of Materials Research and Technology, Vol. 15 https://doi.org/10.1016/j.jmrt.2021.11.034	journal	November 2021
Quantification and characterisation of porosity in selectively laser melted Al–Si10–Mg using X-ray computed tomography Maskery, I.; Aboulkhair, N. T.; Corfield, M. R. Materials Characterization, Vol. 111 https://doi.org/10.1016/j.matchar.2015.12.001	journal	January 2016
Strengthening mechanism of friction stir processed and post heat treated NiAl bronze alloy: Effect of rotation rates Lv, Yuting; Ding, Yang; Han, Yuanfei Materials Science and Engineering: A, Vol. 685 https://doi.org/10.1016/j.msea.2016.12.050	journal	February 2017
Cyclic plasticity at pores and inclusions in cast Al–Si alloys Fan, Jinghong; McDowell, David L.; Horstemeyer, Mark F. Engineering Fracture Mechanics, Vol. 70, Issue 10 https://doi.org/10.1016/S0013-7944(02)00097-8	journal	July 2003
Improvement of microstructure and property of cold-sprayed Cu–4at.%Cr–2at.%Nb alloy by heat treatment Li, W. -Y.; Guo, X. P.; Verdy, C. Scripta Materialia, Vol. 55, Issue 4 https://doi.org/10.1016/j.scriptamat.2006.04.041	journal	August 2006
Fatigue behavior and modeling of additively manufactured IN718: The effect of surface treatments and surface measurement techniques Lee, Seungjong; Shao, Shuai; Wells, Douglas N. Journal of Materials Processing Technology, Vol. 302 https://doi.org/10.1016/j.jmatprotec.2021.117475	journal	April 2022
Fatigue Performance of Laser Additive Manufactured Ti–6Al–4V in Very High Cycle Fatigue Regime up to 109 Cycles Wycisk, Eric; Siddique, Shafaqat; Herzog, Dirk Frontiers in Materials, Vol. 2 https://doi.org/10.3389/fmats.2015.00072	journal	December 2015
Fracture Characteristics and Heat treatment of Laser Powder Bed Fusion additively manufactured GRCop-84 Copper Seltzman, A. H.; Wukitch, S. J. Materials Science and Engineering: A https://doi.org/10.1016/j.msea.2021.141690	journal	July 2021
Recent advances on size effect in metal fatigue under defects: a review Zhu, Shun-Peng; Ai, Yang; Liao, Ding International Journal of Fracture, Vol. 234, Issue 1-2 https://doi.org/10.1007/s10704-021-00526-x	journal	March 2021
Copper-based alloys for structural high-heat-flux applications: a review of development, properties, and performance of Cu-rich Cu–Cr–Nb alloys Minneci, Robert P.; Lass, Eric A.; Bunn, Jeffrey R. International Materials Reviews, Vol. 66, Issue 6 https://doi.org/10.1080/09506608.2020.1821485	journal	October 2020
Microstructure-topology relationship effects on the quasi-static and dynamic behavior of additively manufactured lattice structures Hazeli, Kavan; Babamiri, Behzad Bahrami; Indeck, Joseph Materials & Design, Vol. 176 https://doi.org/10.1016/j.matdes.2019.107826	journal	August 2019
Influence of reversible and non-reversible fatigue on the microstructure and mechanical property evolution of 7075-T6 aluminum alloy Indeck, Joseph; Demeneghi, Gabriel; Mayeur, Jason International Journal of Fatigue, Vol. 145 https://doi.org/10.1016/j.ijfatigue.2020.106094	journal	April 2021
Characterization of bulk to thin wall mechanical response transition in powder bed AM Brown, Ben; Everhart, Wes; Dinardo, Joe Rapid Prototyping Journal, Vol. 22, Issue 5 https://doi.org/10.1108/RPJ-10-2015-0146	journal	August 2016
Directed energy deposition GRCop-42 copper alloy: Characterization and size effects Demeneghi, Gabriel; Barnes, Baxter; Gradl, Paul Materials & Design, Vol. 222 https://doi.org/10.1016/j.matdes.2022.111035	journal	October 2022
Investigation into spatter behavior during selective laser melting of AISI 316L stainless steel powder Liu, Yang; Yang, Yongqiang; Mai, Shuzhen Materials & Design, Vol. 87 https://doi.org/10.1016/j.matdes.2015.08.086	journal	December 2015
Size effect in S–N curves: A fractal approach to finite-life fatigue strength Carpinteri, Andrea; Spagnoli, Andrea; Vantadori, Sabrina International Journal of Fatigue, Vol. 31, Issue 5 https://doi.org/10.1016/j.ijfatigue.2008.10.001	journal	May 2009
Microstructure and mechanical properties of additive manufactured copper alloy Popovich, A.; Sufiiarov, V.; Polozov, I. Materials Letters, Vol. 179 https://doi.org/10.1016/j.matlet.2016.05.064	journal	September 2016
The Effectiveness of Hot Isostatic Pressing for Closing Porosity in Titanium Parts Manufactured by Selective Electron Beam Melting Tammas-Williams, Samuel; Withers, Philip J.; Todd, Iain Metallurgical and Materials Transactions A, Vol. 47, Issue 5 https://doi.org/10.1007/s11661-016-3429-3	journal	March 2016
Effects of specimen size on fatigue life of metallic materials in high‐cycle and very‐high‐cycle fatigue regimes Sun, C.; Zhang, X.; Liu, X. Fatigue & Fracture of Engineering Materials & Structures, Vol. 39, Issue 6 https://doi.org/10.1111/ffe.12415	journal	February 2016
Influence of defects on mechanical properties of Ti–6Al–4V components produced by selective laser melting and electron beam melting Gong, Haijun; Rafi, Khalid; Gu, Hengfeng Materials & Design, Vol. 86 https://doi.org/10.1016/j.matdes.2015.07.147	journal	December 2015
Effects of Post-processing on the Surface Finish, Porosity, Residual Stresses, and Fatigue Performance of Additive Manufactured Metals: A Review Ye, Chang; Zhang, Chaoyi; Zhao, Jingyi Journal of Materials Engineering and Performance, Vol. 30, Issue 9 https://doi.org/10.1007/s11665-021-06021-7	journal	July 2021
Effects of thickness and orientation on the small scale fracture behaviour of additively manufactured Ti-6Al-4V Dzugan, J.; Seifi, M.; Prochazka, R. Materials Characterization, Vol. 143 https://doi.org/10.1016/j.matchar.2018.04.003	journal	September 2018
Damage evolution and failure mechanisms in additively manufactured stainless steel Carlton, Holly D.; Haboub, Abdel; Gallegos, Gilbert F. Materials Science and Engineering: A, Vol. 651 https://doi.org/10.1016/j.msea.2015.10.073	journal	January 2016
Fundamental aspects of hot isostatic pressing: An overview Atkinson, H. V.; Davies, S. Metallurgical and Materials Transactions A, Vol. 31, Issue 12 https://doi.org/10.1007/s11661-000-0078-2	journal	December 2000
Fatigue behavior and modeling for additive manufactured 304L stainless steel: The effect of surface roughness Lee, Seungjong; Pegues, Jonathan W.; Shamsaei, Nima International Journal of Fatigue, Vol. 141 https://doi.org/10.1016/j.ijfatigue.2020.105856	journal	December 2020
Fatigue life distribution and size effect in ductile cast iron for wind turbine components Shirani, M.; Härkegård, G. Engineering Failure Analysis, Vol. 18, Issue 1 https://doi.org/10.1016/j.engfailanal.2010.07.001	journal	January 2011
Fatigue behaviour of additive manufactured materials: An overview of some recent experimental studies on Ti‐6Al‐4V considering various processing and loading direction effects Fatemi, Ali; Molaei, Reza; Simsiriwong, Jutima Fatigue & Fracture of Engineering Materials & Structures, Vol. 42, Issue 5 https://doi.org/10.1111/ffe.13000	journal	February 2019
Estimating the fatigue stress concentration factor of machined surfaces Arola, D.; Williams, C. International Journal of Fatigue, Vol. 24, Issue 9 https://doi.org/10.1016/S0142-1123(02)00012-9	journal	September 2002
Multiaxial fatigue behavior of wrought and additive manufactured Ti-6Al-4V including surface finish effect Fatemi, Ali; Molaei, Reza; Sharifimehr, Shahriar International Journal of Fatigue, Vol. 100 https://doi.org/10.1016/j.ijfatigue.2017.03.044	journal	July 2017
The Effect of Stress Relief on the Mechanical and Fatigue Properties of Additively Manufactured AlSi10Mg Parts Metals, Vol. 9, Issue 11 https://doi.org/10.3390/met9111216	journal	November 2019
Porosity Measurements and Analysis for Metal Additive Manufacturing Process Control Slotwinski, John A.; Garboczi, Edward J.; Hebenstreit, Keith M. Journal of Research of the National Institute of Standards and Technology, Vol. 119 https://doi.org/10.6028/jres.119.019	journal	January 2014
Defects in additive manufactured metals and their effect on fatigue performance: A state-of-the-art review Sanaei, Niloofar; Fatemi, Ali Progress in Materials Science, Vol. 117 https://doi.org/10.1016/j.pmatsci.2020.100724	journal	April 2021
Size Effect on the Fatigue Performance of 18CrNiMo7‐6 Alloy Steel Wang, Gang; Gao, Chen; Zhang, Yue steel research international, Vol. 92, Issue 9 https://doi.org/10.1002/srin.202100054	journal	May 2021
Effects of porosity on the mechanical properties of additively manufactured components: a critical review Al-Maharma, Ahmad Y.; Patil, Sandeep P.; Markert, Bernd Materials Research Express, Vol. 7, Issue 12 https://doi.org/10.1088/2053-1591/abcc5d	journal	December 2020
Non-destructive testing of metal-based additively manufactured parts and processes: a review Rao, Jing; Leong Sing, Swee; Liu, Peipei Virtual and Physical Prototyping, Vol. 18, Issue 1 https://doi.org/10.1080/17452759.2023.2266658	journal	October 2023
Accumulation and evolution of elastically induced defects under cyclic loading: Quantification and subsequent properties Indeck, Joseph; Cuadra, Jefferson; Williams, Cyril International Journal of Fatigue, Vol. 127 https://doi.org/10.1016/j.ijfatigue.2019.05.025	journal	October 2019
Size effects on microstructure and mechanical properties of additively manufactured copper–chromium–niobium alloy Demeneghi, Gabriel; Barnes, Baxter; Gradl, Paul Materials Science and Engineering: A, Vol. 820 https://doi.org/10.1016/j.msea.2021.141511	journal	July 2021

Similar Records

Brazing characteristics, microstructure, and wettability of laser powder bed fusion additive manufactured GRCop-84 compared to CuCrZr and OFC, and brazing to titanium-zirconium-molybdenum alloy limiters

Journal Article · 2022 · Fusion Engineering and Design · OSTI ID:1977154

Seltzman, Andrew H.; Wukitch, S. J.

GRCop-42: Comparison between laser powder bed fusion and laser powder direct energy deposition

Journal Article · 2024 · Additive Manufacturing Letters · OSTI ID:2406764

Demeneghi, Gabriel; Gradl, Paul; Mayeur, Jason R.; +1 more

Fracture characteristics and heat treatment of laser powder bed fusion additively manufactured GRCop-84 copper

Journal Article · 2021 · Materials Science and Engineering. A, Structural Materials: Properties, Microstructure and Processing · OSTI ID:1977462

Seltzman, A. H.; Wukitch, S. J.

Related Subjects

36 MATERIALS SCIENCE
additive manufacturing
thin wall
size effects
porosity
tensile test
fatigue

Title: Size effect characteristics and influences on fatigue behavior of laser powder bed fusion of thin wall GRCop-42 copper alloy

Citation Formats

References (38)

Similar Records

Related Subjects